I was told I couldn't get my 4Runner aligned because it needed a new Idler Arm and a new Pitman Arm. The shop quoted me something over $400 for the parts/labor, I said no-thanks. I picked up an Idler arm and swapped out the old one...piece of cake. The Pitman Arm had to be ordered and was expected next day. I picked it up along with a puller and got to work. Broke that puller and fuct that whole day(yesterday). Today, went back to the parts store, exchanged the pitman arm puller, went back home and got to work. Finally got the old pitman arm off, put the new one on and tightened every thing down and found a problem.

The castle nut threads too far up on the stud so that the cotter pin is useless. If I try and remove the part, I'll damage it and be stuck with the cost. Could I use a nut, torqued to spec, to push the castle nut out far enough that it engages with the cotter pin?

I've been trying to get this 4Runner roadworthy all week. I need it for a camping trip this weekend.

I'm broke and frustrated and don't know if I've fixed my vehicle or just made it worse.

That's what Iwas thinking, don't shim it with washers, torque the spacer nut and then use the castle nut as a lock nut(locking it against replacement nut) and then use cotter pin. By the way, did they sell you the wrong part? Just thinking wht the difference in old and new threaded ends??

You have no idea how relieved I am that you even know what I'm talking about. The Pitman arm fits the shaft splines fine, just on the other end, the stud was longer than the old one and the castle nut was a different size. The threads were the same though. I dunno, I put both castle nuts on and was able to do what I 1st suggested.
I don't want to get laughed out of a garage when I try to get it alligned.